Designation: D 5796 03
Standard Test Method for
Measurement of Dry Film Thickness of Thin-Film Coil-
Coated Systems by Destructive Means Using a Boring
Device1
This standard is issued under the fixed designation D 5796; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
1. Scope
1.1 This test method covers the measurement of dry film
thickness (DFT) of coating films by microscopic observation of
a precision-cut, shallow-angle crater bored into the coating
film. This crater reveals cross sectional layers appearing as
rings, whose width is proportional to the depth of the coating
layer(s) and allows for direct calculation of dry film thickness.
1.1.1 The Apparatus, Procedure, and Precision and Bias
discussions include Method A and Method B. Method A
involves the use of an optical measurement apparatus which is
no longer commercially available, but remains a valid method
of dry film measurement. Method B is a software driven
measurement procedure that supersedes Method A.
1.2 The substrate may be any rigid, metallic material, such
as cold-rolled steel, hot-dipped galvanized steel, aluminum,
etc. The substrate must be planar with the exception of
substrates exhibiting coil set, which may be held level by the
use of the clamping tool on the drilling device.
NOTE 1Variations in the surface profile of the substrate may result in
misrepresentative organic coating thickness readings. This condition may
exist over substrates such as hot-dipped, coated steel sheet. This is true of
all precision cut methods that are used to determine dry film thickness
of organic coatings. This is why several measurements across the strip
may be useful if substrate surface profile is suspect.
1.3 The range of thickness measurement is 0 to 3.5 mils (0
to 89 m).
NOTE 2For DFT measurements of films greater than 3.5 mils (89m),
but less than 63 mils (1600 m), a 45 borer may be used in accordance
with this test method, with the exception of 6.8, where the micrometer
reading would provide a direct read-out, and division by ten would be
unnecessary per 4.3.1 Method A.
1.4 Measurements may be made on coil-coated sheet, cer-
tain formed products, or on test panels.
1.5 The values stated in SI units are to be regarded as the
standard. The values given in parentheses are for information
only.
1
This test method is under the jurisdiction of ASTM Committee D01 on Paint
and Related Coatings, Materials, and Applications and is the direct responsibility of
Subcommittee D01.53 on Coil Coated Metal.
Current edition approved May 10, 2003. Published June 2003. Originally
approved in 1995. Last previous edition approved in 1999 as D 5796 99.
Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
1
1.6 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appro-
priate safety and health practices and determine the applica-
bility of regulatory limitations prior to use.
2. Referenced Documents
2.1 ASTM Standards:
D 3794 Guide for Testing Coil Coatings2
3. Significance and Use
3.1 Measurement of dry film thickness of organic coatings
by physically cutting through the film and optically observing
and measuring the thickness offers the advantage of direct
measurement as compared with nondestructive means.
3.2 Constituent coating layers of an overall thickness of a
coating system can usually be measured individually by this
test method, provide adhesion between each layer is sufficient.
(However, this can be difficult in cases where the primer,
topcoat, or multiple coating layers have the same, or very
similar, appearance.)
4. Apparatus
4.1 Dry Film Thickness Device,3 It is an apparatus consist-
ing of either a manual or automated carbide-tipped drill that
raises and lowers the boring tip perpendicular to the surface to
be tested, a cleaning brush, a marking device (optional), and a
video imaging system, which is attached to a microscope that
views the crater formed by the boring device.
4.2 Carbide Borer Bit, The configuration is designed to
provide a very smooth circular incision in the paint film at a
precise angle to the surface (see Fig. 1).4
4.3 Optical Magnification:
2
Annual Book of ASTM Standards, Vol 06.02.
3
The sole source of supply of the dry film thickness device known to the
committee at this time is DJH Designs, 2366 Wyecroft Rd., Unit D4, Oakville, Ont.,
Canada L6L 6M1. If you are aware of alternative suppliers, please provide this
information to ASTM International Headquarters. Your comments will receive
careful consideration at a meeting of the responsible technical committee, which
you may attend.
4
The manufactured angle formed between the surface of the coating and the
substrate is 5 42 389 and the resulting crater is circular.
 D 5796 03
NOTE 1The drawing is not to scale. It is for illustration purposes only.
NOTE 2u = 5 42 389
Tan u = A/B = 0.1
A = 0.1B
FIG. 1 Typical Crater Formed by Boring Device
4.3.1 Method A, Video CameraIt is attached to an illumi-
nated microscope and conveys the image onto a closed-circuit
television (CCTV) monitor, so that it is an easy matter to line
up the cross-hair on the enlarged image. This very effectively
minimizes error or lack of consistency on the part of the
operator in lining up the cross-hair.
4.3.2 Method B, Computer MonitorIt is attached to a
microscope with external lighting and conveys the image via
software onto a computer monitor. The monitor and software
enlarge the image for viewing and measuring, while the
computer retains the picture as an image file, if the user desires.
4.4 MicroscopeThe measurement is performed by first
boring a shallow-angle crater of known configuration through
the coating(s) film into the substrate. The microscope facili-
tates viewing and measuring the crater.
4.5 The instrument is calibrated by taking measurements on
a standard, which is traceable to a national standards institu-
tion.5 Calibration is a procedure that is done during setup and
will require recalibration if changes are made to the micro-
scope, boring device, or the camera system. Calibration veri-
fication should be done at intervals agreed upon between the
user and the consumer, but no less often than indicated by the
manufacturer of the measuring device.
5. Test Specimens
5.1 If multiple coats of paint are to be measured, successive
contiguous coats should be of contrasting colors to aid sharp
discrimination of interfaces (see 3.2).
5.2 Generally, test specimens shall be prepared (as test
panels) or chosen (as sites on a coil-coated sheet) to be
representative of localized coating thickness and variability.
5.3 If test panels are to be laboratory prepared, this should
be done using accepted industry practices, in accordance with
Guide D 3794.
6. Procedure
6.1 Select a test panel or choose a site for thickness
measurement.
5
The supplier of the standard used to generate the precision statement and used
for calibration (silver-plated, copper substrate) is DJH Designs. The DJH Designs
standard is traceable to the NRC, Montreal Road Building M-36, Ottawa, Canada,
K1A 0R6. An additional acceptable standard for calibration (copper and chromium
coating on steel, SRM 1357) may be obtained from NIST, Standard Reference
Materials Program, Building 202, Room 204, Gaithersburg, Maryland 20899. All
standards must be traceable to the National Research Council or the National
Institute of Science and Technology.
2
6.2 Using an appropriate surface marker6 of contrasting
color, mark a line on the surface about 25-mm long and 12-mm
wide. In most cases, the use of a marker is not necessary, but
for certain colors, usually whites, its use may be desirable.
Depending upon the coating and the type of marker used, it is
possible for the marker to be absorbed into the coating, up to
0.2-mils (5-m) deep. This effect can make it difficult to
determine the position of the top edge of the crater. External
fluorescent lighting may be positioned to enhance the image
and eliminate the need for a marker. The use of a marker,
lighting, or marker and lighting shall be agreed upon between
the user and customer.
6.3 Place the test panel on the borer stage (align the marked
line, if required) so that it is positioned under the bit. Clamp the
panel into place.
6.4 With a small brush, clean debris from the borer bit, the
depth stop surface, and the surface of the test panel. Debris
in these areas will result in a shallower and smaller crater, with
consequently inaccurate results.
6.5 Adjust the depth control wheel so that the carbide borer
bit just penetrates the metallic substrate, to avoid undue wear
on the borer tip. This can only be done by trial and error due
to substrate thickness variation.
6.6 If the boring device is automated, follow the instructions
in 6.6.1; if the boring device is manually operated, follow the
instructions in 6.6.2.
6.6.1 Automated Boring DevicePush the button to acti-
vate boring device. Do not make a second stroke into the same
crater; do not allow the borer head to penetrate a previously
tested crater.
6.6.2 Manual Boring DeviceMove the borer head down
in a smooth, slow action to its full travel position, then
immediately return it to its full rest position. Do not allow the
borer head to rest in the down position; ragged edges or
smeared coating may result, rendering accurate film measure-
ment more difficult. Do not make a second stroke into the same
crater; do not allow the borer head to penetrate a previously
tested crater.
6.7 Place the test panel on the measure stage, and locate the
crater on the monitor by moving the panel either with your
hands, or with the two micrometers that control the movement
of the stage.
6.8 If the viewing method is optical, follow the instructions
in 6.8.1; if the viewing method is software generated, follow
the instructions in 6.8.2.
6.8.1 Method A, Optical MeasurementAdjust the zoom
lens to 4.5, re-center the crater, and focus. Align the cross-hair
in the center of the crater, and using the micrometer adjust-
ments that control the vertical and horizontal movement of the
stage, move the cross-hair to the inner edge of the crater in the
paint film for which the film thickness needs to be measured.
Zero the micrometer. Then move the microscope stage with the
micrometer adjustments so that the cross-hairs are aligned at
the rim of the crater in the paint film. Determine the amount of
6
The marker Sanford Sharpiet used by the committee at this time for this test
method is Sanford Corp., Bellwood, IL 60104.
 D 5796 03
travel from the micrometer and divide this reading by ten (10)
to obtain the film thickness of the paint film (see Fig. 2 and Fig.
3).
6.8.1.1 The reading on the micrometer divided by ten will
be the total mils dry film thickness (DFT). Repeat this
procedure on the other side of the crater, and average the two
readings.
6.8.1.2 It may be possible to read both the primer and the
topcoat film thicknesses (or any of the constituent layers of a
multicoat system) separately. To acquire multicoat film mea-
surements, each coating layer must exhibit good adhesion,
which appears as a smooth circular cut without ragged edges or
debris so a definite, visible delineation of the film layers is
possible.
6.8.2 Method B, Software MeasurementAcquire the im-
age by selecting the proper icon on the software menu. Turn the
microscope lens so it zooms out and center the image of the
crater on the screen by turning the micrometers attached to the
stage. Zoom in again to fill the screen with the crater while
adjusting the micrometers to maintain a fix on the image.
Unlike Method A, you are not required to set the zoom at a set FIG. 3 Cross-Hair at Top Edge (Rim) of Crater
level for accurate film thickness measurement. Focus the
microscope and adjust the lighting or other video options
provided to make the picture more refined. Capture the image. 7.1.1 Results of a Thickness DeterminationIf more than
6.8.2.1 Choose the cross-hair icon and center it in the one measurement is made and specific results for each location
middle of the crater. Mark the points of delineation where the are not needed, report the average thickness of all readings and
cross-hair and substrate (and other constituent layers) converge the number of readings taken. It is not necessary to drill more
(see Fig. 4). than one crater, but it is suggested that the maximum number
6.8.2.2 The average readings with respect to the placement of readings be taken in each crater measured.
of the identified points on the cross-hairs will appear on the 7.1.2 Interval of CalibrationReport the agreed upon in-
screen along with the total average film build. The number of terval of calibration and the date the work was completed.
points chosen to measure determines the number average. If 7.1.3 Method Used for TestingNote if Method A or
the user desires, the software will show each reading separately Method B use used to perform the testing. Report the device
on the screen. model used to perform the testing.
7.1.4 Choice of Marker or LightingReport the type of
7. Report marker used, if any, and what light source was used.
7.1 Report the following information: 7.1.5 Additional Information to ConsiderReport the iden-
tification of the coating(s) or sample(s) examined. Consider
including a physically descriptive form of the test substrate,
(for example, lab applied hot-dipped steel test panel, line
applied cold rolled steel sample), the parameters of application
and pertinent physical properties.

8. Precision and Bias

8.1 PrecisionStatistical analysis of an intralaboratory (re-
peatability) and interlaboratory (reproducibility) round robin
study (conducted using silver-on-copper standards, identified
as Materials 1006, 1088, and 1105) yielded separate results for
the use of the automated boring device (described in 6.6.1) and
the manual boring device (described in 6.6.2).
8.1.1 Precision Statement for the Automated Boring Devi-
ce: Precision, characterized by repeatability, Sr, r, and repro-
ducibility, SR, and R, has been determined for the following
materials to be:
Materials Average Sr SR r R
1006 0.87889 0.05637 0.06987 0.15784 0.19563
1088 1.01000 0.02698 0.04207 0.07554 0.11779
1104 0.91333 0.04372 0.05596 0.12241 0.15670
1105 0.86389 0.02494 0.02755 0.06984 0.07713
FIG. 2 Cross-Hair at Bottom (Inner Edge) of Crater

3
 D 5796 03

FIG. 4 Method B Cross-Hair View, Measuring the Crater

8.1.1.1 RepeatabilityTwo results obtained by the same 8.1.2.2 ReproducibilityTwo results obtained by operators
operator using the automated boring device should be consid- using the manual boring device in different laboratories should
ered suspect if they differ by more than 0.11 mils (2.75 m). be considered suspect if they differ by more than 0.17 mils
8.1.1.2 ReproducibilityTwo results obtained by operators (4.25 m).
using the automated boring device in different laboratories 8.2 Method B, PrecisionWork is underway to determine
should be considered suspect if they differ by more than 0.14 the precision of test method B, and it will be reported in a
mils (3.50 m). future revision.
8.1.2 Precision Statement for the Manual Boring Device:
Precision, characterized by repeatability, Sr, r, and reproduc- 8.3 Method A and B, BiasWork is underway to determine
ibility, SR, and R, has been determined for the following the bias of test methods A and B, and they will be reported in
materials to be: a future revision.
Materials Average Sr SR r R
9. Keywords
1006 0.90050 0.04228 0.06752 0.11838 0.18906
1088 1.04150 0.03678 0.07761 0.10298 0.21731 9.1 borer bit; boring; crater; destructive; dry film; measure
1104 0.92122 0.01724 0.04644 0.04826 0.13003
1105 0.90367 0.01936 0.04446 0.05422 0.12450 stage; micrometer; optical measurement; thickness; thin films;
video camera
8.1.2.1 RepeatabilityTwo results obtained by the same
operator using the manual boring device should be considered
suspect if they differ by more than 0.08 mils (2.00 m).

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